YULEX® CLOSED-CELL FOAM

WHAT IS YULEX®?

Yulex® is the first natural rubber designed as a sustainable alternative to chloroprene rubbers, representing a significant step toward greater environmental responsibility in the synthetic materials industry.

Yulex® foam is made using a combination of renewable resources and sustainable agricultural practices, thus reducing environmental impact compared to traditional materials.

Many brands in the watersports industry have adopted it, recognizing its potential not only for its functional qualities but also for its commitment to sustainability.

HOW IS YULEX® RUBBER PRODUCED?

The natural rubber emulsion comes exclusively from sustainably managed and PEFC and FSC® certified plantations of Hevea brasiliensis trees.

After the latex is extracted from the tree, the emulsion undergoes a refining and purification process to remove impurities such as proteins, oils and residues.

The emulsion is then concentrated and coagulated, and then mixed with high-quality ingredients, resulting in a solid gum. Subsequently, this gum is rinsed, ground and dried, ready to be processed into the so-called Yulex Pure® gum ‘breads’.

As a final step, Yulex rubber breads are cut to give rise to individual sheets, which, once laminated with fabrics, will be ready to be processed.

In the image below you can see all the stages of production. If you would like to learn more about the production process, click here.

YULEX® CLOSED-CELL FOAM

Yulex® closed-cell foam is a cellular foam composed of closed-cell.

In order to understand the composition of a closed cell foam, it suffices to imagine a honeycomb-like structure, where each small cell represents a cell, which is completely sealed and contains air.

Closed-cell foam cells are closed structures, therefore, liquids, air or other particles are unable to penetrate into it. Closed-cell foams have the characteristic of possessing good compression memory, quickly returning to their initial shape, as well as being water resistant. Le schiume a cellule chiuse si dimostrano così un materiale ideale per tutti gli sport d’acqua o attività che richiedano una barriera dall’acqua.

The image shown represents what is the structure of a closed-cell foam in section. This conformation is achieved through a process called extrusion, in which the rubber is ‘inflated,’ and through expansion these closed-structure micro cells are created.

FEATURES AND APPLICATIONS OF YULEX® CCF

Yulex® closed-cell foam is a plant-based rubber that easily replaces neoprene in thousands of applications:

Elasticity and durability for unparalleled performance
Different densities
Exceptional elasticity
Microcellular structure
Water-proof
Ozone and UV resistance

Yulex Rubber® closed-cell can be used in the same manner and with the same processing techniques as neoprene:

Laser cutting
Die-cutting and kiss-cutting
Cutting with blade, scissors
Edge bonding
Stitching and seam sealing

The technical specifications of closed-cell foam, regarding elongation, tear strength, modulus and density, are generally evaluated on pure rubber (without any lamination). This is important to consider, as foam is rarely used without fabrics; therefore, it is crucial to keep this in mind when going to compare Yulex CCF rubber with other rubbers.

The choice of fabrics plays a crucial role in highlighting the physical properties of closed-cell foam. Different types of fabrics have different degrees of elasticity, abrasion resistance, and feel, so selecting the appropriate fabric can improve the performance of Yulex® foam.

For applications requiring high mobility, such as water sports, highly elastic fabrics are preferred, as they allow complete freedom of total movement without hindering actions.

On the other hand, low stretch fabrics are suitable for ancillary applications or products that require limited movement, such as footwear components, garment inserts, bags, backpacks or cases. Low stretch fabrics provide shape, structure and high levels of stability

By carefully evaluating the properties of the foam and the intended use of the product, choosing the right fabrics can optimize the performance of Yulex® rubber.

Fields of application:

Wet suits, dry suits
Swimwear
Footwear
Bags, backpacks
Accessories
Clothing
Braces and supports

HOW MANY TYPES OF YULEX® SHEETS ARE THERE?

Before diving into the fun part, it is important to mention that Yulex closed-cell foams are exclusively available in sheets whose approximate dimensions are 120 x 210 cm with a tolerance of +/- 5 percent.

When it comes to choosing the right type of sheet, it is important to identify 4 main aspects: foam, thickness, lamination, and fabrics.

RUBBER

Yulex® closed-cell is available in different ‘compounds,’ which differ mainly in elasticity, density and memory.

For example, Yulex sheets with high elasticity and good memory may be ideal for making wetsuits or products that require a high degree of movement; conversely, Yulex sheets with high density and low elasticity may be recommended in footwear or accessories in general.

Laminating

The term “lamination” refers to the manufacturing process by which fabric is laminated, then glued, onto the surface of the sheet.

All fabrics laminated on Yulex sheets are exclusively glued with water-based glues.

There are two types of lamination: single or double.

Single lamination: the fabric is laminated on only one side of the sheet. A single-laminated sheet is also called single-lined. The side of the sheet that does not have the lining is called ‘split’.
Double lamination: the fabric is laminated on both sides of the sheet. A double-laminated sheet is also called bifolded; bifolded sheets can have different fabrics laminated on both sides.

No lamination: the sheet has no fabric.

Fabrics

Yulex Rubber® closed-cell is available in a wide combination of fabrics and colors. The main fabrics covered are polyester or nylon base, both available in virgin or recycled yarn versions.

It is possible to laminate specific fabrics upon request.